Vacuum-Formed Infill Structures for Textured Bladder Exteriors
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Solution Overview
Problem
Existing bladders in footwear and apparel are often visible and lack aesthetic appeal, requiring designs that compromise with the overall appearance of the article.
Innovation Solution
A method and system for forming an infill structure using a base mold with vacuum ports and thermoforming techniques to create a textured exterior surface on the infill material, which is then integrated into a bladder to enhance its appearance and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If bladders are concealed within a sole structure, then aesthetic appearance is improved, but visibility of the bladder for design customization is worsened
Solution Approach 1:
The bladder assembly is segmented into two functional parts: the bladder itself for cushioning and a separate infill structure for aesthetic design. This allows the bladder to be concealed while the infill provides visible design elements that can be customized independently.
Solution Approach 2:
The infill structure is positioned to surround and enclose the bladder, creating a nested configuration where the aesthetic infill contains the functional bladder. This nesting allows the bladder to remain hidden while the infill provides the visible design surface.
2Ease of manufacture
If bladders are made visible through openings in the midsole, then design customization is improved, but aesthetic appearance is worsened due to large openings compromising appearance
Solution Approach 1:
The infill structure provides localized aesthetic quality by covering specific visible portions of the bladder while allowing other portions to remain concealed. This enables selective customization of appearance-critical areas without compromising overall aesthetic integrity.
3Manufacturing precision
If infill material is molded using vacuum ports, then manufacturing precision is improved, but device complexity is worsened
Solution Approach 1:
The mold system uses vacuum ports to apply negative pressure and draw the infill material into contact with the mold surface, creating precise surface textures. This pneumatic mechanism provides controlled, repeatable formation of aesthetic surface patterns without requiring complex mechanical pressing systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for the creation of visually appealing and functional infill structures that complement the article's design while providing enhanced cushioning and responsiveness.
Implementation Method 1
applying a vacuum through the plurality of vacuum ports and to the first surface of the infill material to draw the infill material into contact with the mold surface
Data Source
AI summary
A method includes forming a base mold including a base surface, a mold surface formed on an opposite side of the base mold, and a plurality of vacuum ports extending between the base mold and the mold surface and positioning an infill material on the base mold, the infill material including a first surface in contact with the mold surface and a second surface formed on an opposite side of the infill material than the first surface. The method also includes applying a vacuum through the plurality of vacuum ports and to the first surface of the infill material to draw the infill material into contact with the mold surface and inserting the infill material into an interior void of a bladder.